Engine Top Side Disassembly - Suzuki kq750 Service Manual

1D-17 Engine Mechanical:
• Install the rear brake cable clamp (5).
5
4
(c)
• Install the rear brake pedal. Refer to "Rear Brake
Pedal Removal and Installation in Section 4A
(Page 4A-14)".
• Install the exhaust pipe assembly and muffler. Refer to
"Exhaust Pipe / Muffler Removal and Installation in
Section 1K (Page 1K-2)".
• Install the shift lever assembly. Refer to "Shift Lever
Assembly Removal and Installation in Section 5A
(Page 5A-24)".
• Install the throttle body. Refer to "Throttle Body
Removal and Installation (Page 1D-9)".
• After remounting the engine, route the wiring harness,
cable and hoses properly. Refer to "Wiring Harness
Routing Diagram in Section 9A (Page 9A-4)", "Throttle
Cable Routing Diagram (Page 1D-1)" and "Water
Hose Routing Diagram in Section 1F (Page 1F-3)".
• Pour engine coolant and engine oil. Refer to "Cooling
System Inspection in Section 0B (Page 0B-15)" and
"Engine Oil and Filter Replacement in Section 0B
(Page 0B-10)".
• After finishing the engine installation, check the
following items:
– Throttle cable play
Refer to "Throttle Cable Play Inspection and
Adjustment in Section 0B (Page 0B-15)".
– Rear brake cable play
Refer to "Rear Brake Pedal / Rear Brake (Parking
Brake) Lever Inspection and Adjustment in Section
0B (Page 0B-19)".
– Parking Brake cable play
Refer to "Rear Brake Pedal / Rear Brake (Parking
Brake) Lever Inspection and Adjustment in Section
0B (Page 0B-19)".
– Engine oil and coolant leakage
Refer to "Cooling Circuit Inspection in Section 1F
(Page 1F-4)".
4
(d)
I831G1140071-04

Engine Top Side Disassembly

It is unnecessary to remove the engine assembly from
the frame when servicing the engine top side.
CAUTION
!
Identify the position of each removed part.
Organize the parts in their respective groups
(e.g., intake, exhaust) so that they can be
reinstalled in their original positions.
1) Drain engine coolant. Refer to "Cooling System
Inspection in Section 0B (Page 0B-15)".
2) Remove the seat. Refer to "Seat Removal and
Installation in Section 9D (Page 9D-11)".
3) Remove the battery.
CAUTION
!
When disconnecting the battery lead wires,
be sure to disconnect the battery (–) lead
wire first.
4) Remove the front fender and left mud guard. Refer to
"Front Side Exterior Parts Removal and Installation
in Section 9D (Page 9D-6)" and "Rear Side Exterior
Parts Removal and Installation in Section 9D
(Page 9D-9)".
5) Remove the shift lever assembly. Refer to "Shift
Lever Assembly Removal and Installation in Section
5A (Page 5A-24)".
6) Remove the air cleaner box. Refer to "Air Cleaner
Box Removal and Installation (Page 1D-5)".
7) Remove the throttle body. Refer to "Throttle Body
Removal and Installation (Page 1D-9)".
B831G21406015
I831G1140072-01